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Cover Sheet

Operating Manual

Air Cooler
PRELIMINARY

Customer

Armax Gaz S.A. Strada Aurel Vlaicu, Nr. 35A 551014 Sibiu Romania

Customers order No. Codeword Item No. Engineering

3395/29.06.2011 GDU 01-EA-100 / 02-EA-100 GEA Luftkhler GmbH Dorstener Strae 484 D-44809 Bochum

GEA Project No.

G-1225077/10+30

This Operating Manual is protected by copyright and exclusively serves the purpose contractually agreed between Dez 2011 Rev. 0 GEA Luftkhler Chapter 1 Service and Support Page 1 of 63 customer and manufacturer. Any use other than intended which includes reproduction of the entire or partial document in whatever form as well as utilization of its contents or parts thereof is prohibited unless the express written approval of the manufacturer has been obtained. In the event of contraventions compensation for damages will be claimed. Moreover, further claims will be raised as deemed necessary.

Overview Table of Contents


1 2 Service and Support ........................................................................................................... 4 Introduction ....................................................................................................................... 5 2.1 2.2 2.3 2.4 2.5 2.6 3 4 3.1 4.1 Preface ...................................................................................................................... 5 Owners Responsibility ............................................................................................ 6 Application Purpose ................................................................................................ 8 Operating Principle ................................................................................................. 9 Overview of Air Cooler Components ................................................................... 10 Safety Instructions ................................................................................................. 11 Gas Coolers ............................................................................................................. 16 Air Cooler Control.................................................................................................. 18 Switching Off Fans ................................................................................................. 19 Control via Frequency Converter .......................................................................... 19 Blade Adjustment .................................................................................................. 20 4.2 5 5.1 Measures during Cold Periods .............................................................................. 21 Gas Coolers ............................................................................................................. 23 Empty the Tube Bundle ......................................................................................... 23 Drying ..................................................................................................................... 24 Nitrogen Filling ...................................................................................................... 24 6 Maintenance .................................................................................................................... 25 6.1 Tube Bundle ........................................................................................................... 25 Cleaning of Tube Bundles ..................................................................................... 26 Cleaning the Tubes Inside ..................................................................................... 26 Bolt Tightening Sequence for Flanged Connections ........................................... 28 Cleaning the Tubes Outside .................................................................................. 29 Checks for Corrosion ............................................................................................. 30 Tube Bundle Troubleshooting .............................................................................. 31 Repairs .................................................................................................................... 32 6.2 Fan Drives ............................................................................................................... 33 Maintenance Intervals of Fan Drives .................................................................... 34 Cleaning the Fan Drive .......................................................................................... 36 Checking the Fan Drives ........................................................................................ 36 Taking the Plant out of Service....................................................................................... 23

Commissioning ................................................................................................................. 16 Operation ......................................................................................................................... 18

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Overview
Belt Replacement ................................................................................................... 37 Fan Bearing System ............................................................................................... 37 Fan Drive Troubleshooting ................................................................................... 40 Annex to the Fan Drive Chapter ........................................................................... 43 6.3 Louvers ................................................................................................................... 44 Louvers Maintenance Intervals ............................................................................. 44 Cleaning ................................................................................................................. 44 Checks ..................................................................................................................... 44 Louvers Troubleshooting ...................................................................................... 45 Annex pertinent to the louvers ............................................................................ 45 7 Transportation and Storage ............................................................................................ 46 7.1 7.2 8 Transportation ....................................................................................................... 46 Packing and Marking ............................................................................................ 46 Storage ................................................................................................................... 48 Storage Exceeding Three Months......................................................................... 50 Erection ............................................................................................................................. 51 8.1 8.2 Verifying Prerequisites .......................................................................................... 51 Mounting the Steel Structure ............................................................................... 52 Preassembly of Steel Structure Elements ............................................................. 53 Erecting the Steel Structure .................................................................................. 55 Aligning the Steel Structure Elements ................................................................. 56 8.3 Mounting of Fan Drives ........................................................................................ 57 Preassemble the Fan Drive System ....................................................................... 57 Installing the Fan Drives ........................................................................................ 58 8.4 8.5 Installing the Tube Bundles .................................................................................. 59 Installation Instructions ......................................................................................... 61 Notes on the Installation of the Pipework .......................................................... 61 Notes on Electrical Equipment Installation .......................................................... 61 8.6 9 10 Fan Trial Run .......................................................................................................... 63 Disposal ............................................................................................................................. 64 Annex ................................................................................................................................ 65 10.1 Overview - Maintenance Intervals ........................................................................ 65 10.2 Air Cooler Data Sheet ............................................................................................ 66 10.3 Design Drawings .................................................................................................... 66 10.4 List of Spares .......................................................................................................... 66

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Contact

1 Service and Support


Your Team at GEA Luftkhler GmbH
Project Management Contact your Project Manager to discuss any issues in relation to your project: Jrg Gaidell Dept. TAAP Phone Fax E-mail Installation and Service Our installation and service staff provides assistance for: Erection/installation activities Adjustment of fans and louvers Maintenance and repair work Spare parts Phone Fax E-mail Phone Fax E-mail +49 (0)234/980-1744 +49 (0)234/980-2018 waldemar.nowinski@geagroup.com +49 (0)234/980-1742 +49 (0)234/980-2018 birgit.bordiuk@geagroup.com +49 (0)234/980-1653 +49 (0)234/980-1974 joerg.gaidell@geagroup.com

Waldemar Nowinski Dept. TAS (Installation, repairs etc.) Ms. Birgit Bordiuk Dept. TASE (Miscellaneous spares) Sales

Our project engineers will be glad to help you find solutions tailored to your application. Please contact our Sales Manager: Jrg Brggemann Dept. TAV Phone Fax +49 (0)234/980-1953 +49 (0)234/980-2014

E-mail joerg.brueggemann@geagroup.com If you submit questions or look for information please state Our project number Our drawing number Designation/item number Brief description of the issue

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Preface

2 Introduction
2.1 Preface
This operating manual serves for installation, commissioning, operation as well as maintenance of the air cooler. Any information needed for this has been organized according to assembly groups. The operating manual forms part of the supply scope and must be safely stored by the Owner such that it is readily available. Before work is performed on the air cooler the operating manual is to be handed to the person working on the unit. After work has been completed the manual is to be given back to the Owner. Documents supplementing the operating manual: Design drawings by GEA Luftkhler GmbH (included in the Annex) Documentation furnished by suppliers of bought-out items (included in the chapters dealing with the assembly groups) as well as Operating instructions issued by the Owner. Before carrying out work the person performing such work must read the following thoroughly and completely: This Introduction chapter, the relevant chapter, the respective documents included in the Annex, the relevant topic in the Owners operating instructions, for installation purposes the Installation chapter and the design drawings included in the respective chapter in the Annex.

Attention!
The instructions given in this operating manual must be observed. Disregard may endanger persons, cause damage to the air cooler and lead to warranty and liability claims becoming forfeited.

Note:
Any figures and descriptions contained in this manual shall only be regarded as being analogous because an air cooler consists of several assembly groups and components that may be combined and designed differently. As regards the air cooler furnished the relevant documents included in the supply such as design drawings, data sheets and delivery note shall apply.

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Owners Responsibility 2.2 Owners Responsibility


Note:
The Owners responsibility is directly linked to the intended air cooler service (product handled, operating conditions, integration into the overall plant etc.). Some activities may not be necessary, others may have to be added. The course of action to be followed by the Owner shall take into account statutory provisions, safety aspects and other prerequisites. The Owner must prepare operating instructions, in particular covering the following aspects: Information about the air cooler in the context of other plant units and the product passed through the tube bundle; Operation, maintenance intervals and work required on account of the overall plant and the product handled; Steps required during cold periods to prevent the air cooler from freezing up or the product flow from slowing down or stopping; The arrangement of feeder lines, shut-off valving, safety equipment etc.; The characteristics of the products transferred through the tube bundle and how to handle these substances in view of statutory provisions and relevant safety data sheets; Instructions aimed at checking the safety equipment regularly and how to behave in the event of disturbances and during emergencies. Moreover, take action as follows: Make sure all safety, accident prevention and environmental provisions currently applicable to the air coolers range of application are observed. Make sure safety equipment such as emergency stop switches are mounted near motors and barriers are arranged to prevent unauthorized access to the extent viewed expedient. Determine by way of a risk analysis the dangers associated with the use of the air cooler (for example due to certain products or adjacent plant units). Make sure at regular intervals that the operating instructions you prepared reflect the current state of applicable regulations and standards. Determine who is responsible for the work to be performed on the air cooler.

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Owners Responsibility
Brief operators about the safe operation of the air cooler, in particular point out steps to be taken for start-up, operation and taking the equipment out of operation. Instruct operators with respect to relevant maintenance intervals and brief them on the maintenance activities necessary. Advise all persons working with the air cooler of the dangers involved and instruct them how to behave in case of disturbances and emergencies. Moreover, familiarize all these persons with this operating manual, in particular with the Chapter Service and Support starting on page 4Service and Support the Chapter Introduction starting on page 5 the individual chapters pertaining to a given activity. Provide regular training for all these persons.

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Function and Design 2.3 Application Purpose


The air cooler is intended for the cooling of products such as liquids, vapors and gases. It must only be employed for the intended purpose for which it has been designed by GEA Luftkhler GmbH. The permissible operating conditions are laid down in the air cooler data sheet and design drawings (in Chapter Annex starting on page 65). If it is desired to change the application purpose the Owner must verify whether the air cooler is suitable and can be approved for the new service.

Note:
GEA Luftkhler GmbH shall not be liable for damage resulting from the air cooler being used for other than the intended purpose.

Note:
Reconstruction of and modifications to the air cooler are only admissible with GEA Luftkhler GmbHs permission.

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Function and Design 2.4 Operating Principle


The product to be cooled passes through the tubes of the tube bundle. To improve the transfer of heat to the air the tubes are as a rule equipped with fins. At both ends of the tube bundles headers are arranged which serve to distribute the product to the tubes and collect it at the opposite end. The fin tubes are expanded into the tubesheet. By means of motor driven fans of forced-draft type the air is passed around the tubes outer surfaces. Fan rings are arranged to pass the air into the plenum chambers via which it is distributed over the tube bundle.

Air discharged (hot air)

Product IN (hot)

Product OUT (cold)

Air intake (air at ambient temperature)

The tube bundle is usually of stilted design using a supporting steel structure which enables the air to be drawn in from below via the fan. For maintenance purposes the steel structure is often provided with walkways, handrails and access ladders. To prevent the cooler from freezing up when the flow of product has been stopped and the fans switched off heating bundles may optionally be arranged below the tube bundle and louvers mounted above the tube bundle. The heating bundles serve to heat the product inside the tube bundles. Louvers are provided to cover the tube bundles and thus shall prevent free or natural convection.

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Function and Design 2.5 Overview of Air Cooler Components


Air cooler (all figures to be regarded analogous) Header Louver Header Platform Handrail Guard cage

Tube bundle Heating bundle Plenum chamber

Access ladder

Protective guard

Bracing

Support Motor bracket

Fan impeller ring

Fan bridge

Fan blade

Fan hub V-belt pulleys V-belt Fan support Tubesheet Motor Venting flange

Tube bundle (entire unit)

Draining flange

Inlet flange

Header Fin

Outlet flange Tube

Fin tube (entire unit)

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Safety 2.6 Safety Instructions


Safety Symbols
Warning against hazards of general nature to persons, the environment and/or objects in case of maintenance, disturbances and repairs: Take air cooler out of service at once. Switch off the power supply to all drives. Stop the flow of product, allow product to cool down and depressurize, if necessary empty the tube bundle. Dispose of the product as prescribed. Notify other persons that the unit has been taken out of operation. If necessary, make sure the unit cannot be restarted. Observe accident prevention rules and company-own instructions regarding safety at work. Take steps to have the cause of the failure remedied by expert personnel without delay. Do not restart the air cooler before remedial work has been completed and approved.

Warning that hand injuries, contusion and other bodily injuries may be caused. Do NOT remove safety and protective system or components, never reach into drives or linkage, e.g. fan drive, positioning cylinders, actuators for louvers etc. Do not start working on drives before you have convinced yourself that they have positively stopped and been secured to prevent movement. Warning of falling risks. Work on the air cooler must only be performed under safe working condition, having gained firm and secure foothold, when safeguarded and with due attention paid and a precautionary approach taken. Warning that bodily injuries may occur due to suspended loads. Only employ suitable and approved lifting equipment. Secure loads to prevent slipping and overturning during lifting.

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Safety

Warning against danger caused by product spillage. Before tube and header connections are disconnected the tube bundle must have been depressurized and cooled down. The tube bundle must be empty and free from harmful or dangerous substances. The product must be collected and disposed of, if necessary. Only if all security concerns have been eliminated may work be carried out on the tube bundle. Warning that danger to life is imminent due to electric shock. Prior to start of work the power supply must be switched off and secured to prevent restarting, e.g. fan, louver drive units etc. Warning against burning hazards caused by hot fin tubes, headers and pipework connections, fittings, valves etc.

Warning that personal protective workwear must be worn when carrying out work on the air cooler, especially snug-fitting clothes, safety gloves, protective footwear and hard hat, otherwise risk of injuries. Warning that hearing protection must be worn when carrying out work near fan drives, otherwise risk of hearing damage or disorder.

Sign indicates a necessary course of action and additional information.

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Start-up of Air Cooler

3 Commissioning
Prior to commissioning make sure that all persons concerned have been informed about work steps to be taken and alerted to special risks associated with commissioning and startup work. Point out to them how to behave in cases of faults and emergencies; all handling, lifting and erection equipment has been removed; the headers of the tube bundles can freely expand; the space below the supporting steel structure is unobstructed allowing all fans to take in air as necessary; the fan drivers are not blocked; all parts of the air cooler especially the fan drives and tube bundles are free from dirt as well as snow and ice. as a result of connecting or adapting pipework no dirt or residual matter has entered the product header of the tube bundle.

Note:
Despite careful cleaning during production process we cannot ensure absolute cleanliness of the heat exchangers. To avoid damage to downstream components caused by contamination/dirt, close meshed temporary filters must always be mounted for commissioning the equipment. After plant commissioning these filters are to be checked for soiling and cleaned if necessary. These filters can be removed after a continuous period of operation sufficiently long to make sure the filters no longer contain soiling/dirt. Damages due to contamination/dirt are excluded from our warranty!

3.1

Gas Coolers
Fill the pipework and tube bundles with the medium, at ambient temperature, intended for the operation.

Attention!
When filling in liquid no dirt from feed pipework must enter the tube bundles. Aside from damage capacity losses, tube clogging and tube distortion may otherwise arise which may lead to inadmissible temperature differences and, during cold periods, freeze-up hazards.
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Start-up of Air Cooler


Note:
The temperature of the medium to be filled in must at least be 10 C above the hydrate formation point. It must be made sure that tubes or tube sections cannot freeze up. Vent the tube bundles without delay and circulate the product because flowing product freezes not as easily as stationary product does. Check the entire tube bundle for leakages. The temperature of the tube bundle must be slowly raised until operating temperature is reached. At no point must the temperature increase exceed 50C per minute. Decelerate reversely rotating fans down to standstill by briefly switching the motors on.

Note:
When switching on fan drives not provided with return stops the respective motor protection switch may trip if the fans have reversely rotated before the drives are switched on. When the product temperature approaches the operating conditions proceed as follows: Switch the fans on, if possible at increasing speed, otherwise one after the other. Make sure they run up to speed smoothly and check for unusual noise. During cold periods: Check whether the louvers are affected by snow or ice.

Note:
Waste heat emitted by the tube bundles may be used to defrost icy louvers. To speed up defrosting the fan drives can be briefly turned on, if thought expedient. Open the louvers as soon as snow or ice has been removed.

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Capacity Control during Operation

4 Operation
4.1 Air Cooler Control
Each tube bundle has been designed for the maximum operating conditions that may exist during the hot season as prescribed by the customer (see Air Cooler Data Sheet) so that there is spare capacity for the remaining time of the year. If operating conditions or ambient air temperatures (e.g. day and night time spans) change the air cooler can be adjusted to the new operating requirements by reducing the air flow rate. The air flow or speed of the fans may have to be reduced in particular if it is desired to prevent the product from cooling down inadmissibly, lower the noise emissions, e.g. at night, or save electrical power. When adjustments are made the volume flow behaves proportionally to the fan speed: V 1 /V 2 =n 1 /n 2 Power requirement changes take place proportionally to the 3 power of fan speed changes: P 1 /P 2 =(n 1 /n 2 )
3 rd

Various steps can be taken to control the air coolers: Switching off fans Speed control (only via frequency converters) Blade adjustment

Steps to be taken when the product outlet temperature falls are described below. In the event the product outlet temperature rises the steps shall be implemented analogously in reverse order.

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Capacity Control during Operation


Switching Off Fans
Switching off fans just enables the coolers to be controlled roughly. If the product outlet temperature falls: Switch off the rear fan (i.e. the fan farthest away from the product inlet). Product IN (inlet flange)

front fan

rear fan

Control via Frequency Converter


Frequency converters enable the speed to be steplessly lowered. If the product outlet temperature falls: Reduce the speed of the fans.

Attention!
If frequency converters are employed: The fan must not operate in the resonance range. - Otherwise, severe vibrations may be caused leading to damage and safety risks.

Note:
If the resonance frequency is found to be in the operating range of the fan this resonance/excitation frequency is to be passed through quickly at a waveband of +20 % with the frequency converter being adjusted accordingly.

Note:
We recommend that vibration switches are installed to detect inadmissible vibrations.

Note:
When changing the speed of the fans also observe the operating instructions issued by the manufacturer of the motor and frequency converter included in the Annex to the Fan Drive Chapter starting on page 43 as well as the pertinent fan drive drawing.

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Capacity Control during Operation

Blade Adjustment
Should the fans not equipped with blades adjustable during operation a manual mechanical adjustment is difficult and time-consuming and therefore only considered expedient if long-term temperature changes are expected, e.g. seasonal changes. Before adjusting the blade angle make sure to read and take into account chapter Fan Drives starting on page 33. Change the blade position by adjusting the design angle for large flow rates a smaller blade angle for lower flow rates

After adjustment has been made: Check whether the fan runs smoothly and quietly. Also make sure the maximum allowable power absorption of the motors is not exceeded at high flow rates; in this context refer to the technical data shown on the fan drive drawing.

Note:
When adjusting the fan blades also observe the operating instructions issued by the fan manufacturer and included in Chapter Annex to the Fan Drive Chapter starting on page 43 as well as the pertinent design drawings. Perform the work steps listed in Chapter Fan Trial Run starting on page 63.

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Measures during Cold Periods 4.2 Measures during Cold Periods


Attention!
Freezing of tube bundle portions or the solidification/stagnation of product may lead to damage, loss of function and safety hazards.

Note:
Necessary measures to be adopted to prevent tube bundle portions from freezing up and/or product from solidifying/stagnating depend largely on the type of product handled, the weather conditions to be expected, the design of the plant as well as other circumstances. The Owner must therefore determine the steps that have to be taken when low temperatures prevail; in this context refer to the operating instructions issued by the Owner.

Note:
It is to be noted that the product discharge temperature is not the lowest product temperature within the tube bundle: the lowest product temperature inside the tube bundle exists within the bottommost tube row at the product outlet location. The temperature at the discharge end of the bottommost tubing in the tube bundle is lower than the product temperature measured at the outgoing manifold (tube bundle outlet).

Note:
Nevertheless, if despite all measures taken by the Owner there is still a risk that freezing or product solidification/stagnation occurs in portions of the tube bundle the air cooler has to be shut down without delay; in this context refer to Chapter Taking the Plant out of Service starting on page 23.

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Measures during Cold Periods

Note:
GEA Luftkhler GmbH is unable to warrant the effectiveness of the measures outlined below and cannot be held liable if damage is suffered due to low temperature exposure. Attentively observe the ambient temperature during cold weather (especially when the medium flow has been stopped). The following measures which may to some extent be combined if expedient can be taken in an attempt to prevent the product from freezing or solidifying/stagnating. The effectiveness of the measures taken must be constantly verified through the Owner by appropriate means. However, if freezing or solidification/stagnation hazards still exist despite the precautionary actions implemented the air cooler must be taken out of service without delay. Keep the rate of flow in the tube bundle high enough to make sure hot liquid adequately passes through all fin tubes. Switch off the rear and, if necessary, also the front fan (as viewed in the direction of flow) at each tube bundle. If the flow in the tube bundle has been stopped: Close the louvers or Open the closed louvers only when the blades and linkage are ice-free. Defrosting may be brought about by preheating by means of the tube bundle below, if necessary also activating the fan for this purpose. Start up an additional heating system (for example, an auxiliary heater arranged in the water circuit or air heating units mounted below the tube bundle). Allow the water to circulate (repumping) since water that flows freezes less quickly than stagnant water due to the fact that constant intermixing takes place. However, if despite all steps taken there is still a risk that the product freezes up or solidifies in certain parts of the tube bundle - or in cases of doubt - do the following: Take the air cooler out of service without delay; also refer to Chapter Taking the Plant out of Service starting on page 23.

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Shutting the Air Cooler Down

5 Taking the Plant out of Service


Note:
After the system has been shut down the fan drives must be run for approx. 2 hours once a month to make sure moisture that may have ingressed can evaporate and the bearings are adequately lubricated (motor, fan bearing system etc.). This operation has to be documented. If louvers are mounted they may remain closed during this period.

5.1

Gas Coolers
Switch off the fans. Close off the inlet and outlet point at the tube bundles. Mark the air cooler as having been taken out of service.

At the latest when the ambient air temperature is below/equal to 5 C or if there is danger of frost: Empty the tube bundle if the product contains water.

Empty the Tube Bundle


Depressurize the tube bundles. Carefully empty all tube bundles. For this purpose open all inlet and discharge pipe connections and all draining and venting nozzles. Also empty all other parts of the tubing system. Note: Make sure emptying is carried out carefully, avoid contamination due to oil. Take appropriate steps to dispose of waste oil expertly. Collect or properly dispose of the product.

Note:
If the air cooler shall be shut down for a longer period of time or permanently the tube bundles have to be either dried or filled with nitrogen.

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Shutting the Air Cooler Down

Drying
In case of multi-pass tube bundles: Blow the residual liquid out of the return sections by means of compressed air or extract it by suction. Close the venting and draining lugs. Connect a drier (e.g. a Munters drier) to the inlet or outlet flange(s). Close off all other connections save for one flange on the opposite side (where the hot air will exit). Rule out to the extent possible unnecessary heat losses by covering the fin tubes and dry the tube bundles. After a drying period of one day ascertain - for instance by means of an endoscope - that there is no residual water left in the tube bundles. If it has been determined that no residual water is inside the tube bundles: Close off the inlet and outlet nozzles.

Nitrogen Filling
Close off the flanges and lug closures by means of blank flanges. Attach a pressure gauge as well as a hose connecting cock to one of the blank flanges. Connecting cock and pressure gauge may also be mounted on different blank flanges. Make sure these items do not suffer physical damage. Fill the tube bundle with nitrogen (0.5 bar). Check the pressure gauge monthly and adjust the pressure if necessary.

Note:
In the event of temperature changes the nitrogen pressure will also vary.

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Tube Bundle Maintenance

6 Maintenance
Document all maintenance activities performed indicating date, type of work, name of maintenance person and signature. Attach the document to this operating manual.

Note:
If necessary, the maintenance intervals indicated shall be adapted to suit the relevant operating conditions.

6.1

Tube Bundle
Attention!
Observe the product safety data sheets issued by the Owner. Note that there are serious health and safety hazards due to liquid and fumes/vapors. Tube Bundle Maintenance Intervals We recommend that maintenance be carried out on a monthly basis. Check tube bundles for leaks Check outside of tubes for dirt/contamination/soiling Check whether tube connections and fasteners are firm or tightly seated Check for corrosion

Moreover, statutory provisions as per Operational Safety Ordinance are to be observed with respect to inspection intervals. For pressure vessels this involves: External inspection .......................................................................every 2 years Internal inspection ........................................................................every 5 years Strength inspection.....................................................................every 10 years

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Tube Bundle Maintenance

Cleaning of Tube Bundles


For an appropriate tube bundle functioning clean exchanging surfaces are indispensable. Dirty or foul surfaces will not only impair the transfer of heat but also increase pressure losses on both the product and air side so that ultimately performance drawbacks and damage to the tube bundles will be encountered.

Cleaning the Tubes Inside


Cleaning methods adopted may include, for example cleaning adopting high-pressure water methods; cleaning using brushes; admixing solid particles entrained in the media flow and having abrasive properties such as quartz sand, powdered pumice, fly ash or filter dust; CO2 blasting using compressed air and carbon dioxide particles directed onto the inside tube surfaces via nozzle.

Note:
The inside surfaces of fin tubes must be cleaned on a regular basis if the liquid to be cooled or condensed cause deposits. The cleaning intervals depend on the operating conditions and have to be determined by the Owner.

Note:
Prior to cleaning convince yourself that the desired method can be safely applied to the tube bundle to be cleaned and used for the product to be cooled or condensed. Interrupt the flow of product in the tube bundle to be cleaned and switch off the fan drives safely.

Depending on the relevant cleaning method do the following: Make sure the tube bundle has been emptied and depressurized. Depending on the relevant header type and cleaning method adopted carefully remove the plugs without causing sealing faces and threads to be damaged. Check the inner surfaces of headers and fin tubes for deposits or fouling.

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Tube Bundle Maintenance

In the event of deposits: Clean the inner surfaces of the tubes. Collect the cleaning remnants and dispose of them as prescribed by statutory provisions.

After tube bundle cleaning work has been completed: Check the condition of the inner tube faces (for fouling, corrosion that may still exist). Check all fin tube-to-tubesheet joints for cracks, pores and erosion. Check and clean all sealing faces. Replace plugs that have damaged threads. Have damaged threads recut or otherwise repaired expertly. Mount the plugs. During mounting work install new seals/gaskets. Do not use grease or other substances that may have a detrimental effect on the product later passing through the tubes.

Note:
To facilitate the installation of rectangular seals/gaskets use small adhesive strips in places to keep the seals in position during installation.

Note:
Make sure the adhesive strips cannot come into contact with the product later flowing through the tube bundle and the adhesive does not attack the seals.

In the event of headers without tongue and groove: Stick the seal onto the header sealing face.

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Tube Bundle Maintenance


Bolt Tightening Sequence for Flanged Connections
1. Tighten all bolts at the prescribed torques; in this context refer to the tube bundle drawing included in the Chapter Annex starting on page 65. 2. Tighten the bolts of the round and rectangular flanges as per the numbering sequence shown in the following drawing. 3. When the unit is operated in the high-pressure temperature range retighten all bolts/plugs after 24 hours of operation at the prescribed torques. However, the numbering sequence shown need no longer be observed now.

correct Round flange

wrong Square flange

wrong

Adm. tightening torque Step 1

M A < 100 Nm

M A > 100 Nm to < 300 Nm

M A > 300 Nm to < 800 Nm M A 1 = 50 Nm

M A > 800 Nm

M A 1 = 50% [Nm]

M A 1 = 50 Nm

M A 1 = 50 Nm

Step 2

M A 2 = 100% [Nm]

M A 2 = M A / 2 + 20 Nm M A = 100% [Nm]

M A 2 = 150 Nm

M A 2 = 150 Nm

Step 3

MA 3 = MA /3 + 100 Nm

M A 3 = M A / 4 + 150 Nm MA 4 = MA /2 + 300 Nm M A = 100% [Nm]

Step 4

M A = 100% [Nm]

Step 5

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Tube Bundle Maintenance


Cleaning the Tubes Outside
Fin tubes primarily get dirty at the underside of the tube bundle at the point where the cooling air contacts the tubes with larger dirt particles already accumulating on the first fin tube row. Smaller particles may even enter the second and third tube row. For that reason, cleaning is best done from the upper side of the tube bundle. Interrupt the flow of product in the tube bundle to be cleaned, depressurize the tube bundle and empty it. Disconnect the motors from the power and make sure the fans cannot rotate or be started. Check the tube outer surfaces for dirt or contamination at the prescribed intervals and if it seems the cooling capacity is impaired.

Attention!
Adjust the cleaning pressure and use a cleaning method appropriate to the strength of the respective tube type. Always direct the cleaning jet parallelly to the fin faces. In the event first signs of damage are noticed or if damage is suspected abort the cleaning activities immediately to avoid damage to the fin tubes.

In case of minor dirt deposits or soiling: Carefully clean the tube outside, for example using a steam-jet cleaner. Dry dust may usually be blown away by applying compressed air. In case of more persistent deposits: Clean by applying high-pressure water jets. If necessary, also clean other dirty surfaces of the air cooler.

Note:
Which tube type has been used can be seen from the air cooler data sheet, refer to the Chapter Annex starting on page 65.

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Tube Bundle Maintenance

Tubes with extruded fins made of aluminum (bimetal tubes) are less fragile. Nevertheless, the water pressure must be below 100 bar, the minimum distance to the fin tube to be 2 meters and the jet direction in relation to the tube axis must be possibly 90 plus/minus 10. Cleaning will be easiest if dirt layers have not solidified excessively. Fin tubes may be stepped on with great care only if they have first been covered with scaffolding planks of adequate thickness.

Checks for Corrosion


Check all parts of the air cooler and pipework system for corrosion.

If signs of corrosion are noticed: Eliminate corrosion damage, check whether the remaining wall thickness is operationally safe and renew or protect the surface expertly to rule out new corrosion can occur. If the prescribed wall thickness in the tube bundle or of parts subjected to pressure is fallen below proceed as follows: Reduce the pressure, respectively the temperature of the product as necessary or replace the weakened parts or contact GEA Luftkhler GmbH for advice on what actions have to be taken.

Note:
In this context GEA Luftkhler GmbH is prepared to submit an offer relating to recalculating the strength characteristics and determining maximum pressure as well as maximum temperature values.

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Tube Bundle Maintenance


Tube Bundle Troubleshooting
Poor performance Gas bubbles due to inadequate venting Deposits inside of the tubes or tubes clogged Outer tube surfaces dirty If the product is water: Reduced heat transfer due to water containing a high amount of cooling agent Motors switched off or speed rates reduced The fan blade angle is too small Leakages Joints in the tube system or in the headers are leaky Leakage at the fin tube/tubesheet joints Corrosion

Vent the tube bundle properly Clean the tube inside Clean the outer tube surfaces Increase the water proportion

Check motors and speed Adjust the blade angle

Make sure sealing faces have proper contact; retighten connections in pressureless state, otherwise replace seals/gaskets Reweld or re-expand the connections or both if necessary; otherwise cut off tube and close off the tube holes in the tubesheet Contact GEA Luftkhler GmbH for information on repairs

Bent fin tubes Some tubes are clogged, remain cold and act like tie-rods thus affecting the other tubes Headers are prevented from expanding Bent fins Stepped-on fins are damaged or fins damaged due to objects placed on them

Clear clogged tubes, otherwise cut tubes off and close off tube holes in the tubesheet Take steps to allow expansion, remove any objects that may impede expansion

Do not step on fins before having laid a board, plank or similar pressure spreading object on the fins, be careful when entering; straighten damaged fins using flat-nose pliers Reduce the cleaning pressure and apply jet at a right angle to the fin tube; straighten damaged fins using flat-nose pliers

Damage caused by high-pressure cleaner or similar device

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Tube Bundle Maintenance


Repairs
Note:
A replacement of fin tubes should only be carried out by GEA Luftkhler GmbH.

Tube bundle with plugs - Leakages at the fin tube/tubesheet connections: Remove the plug to gain access to the leaky fin tube/tubesheet connection. Remove the weld seam down to the parent metal by boring or milling. Reweld the leaky joint or roll the tube again into the tubesheet (only possible with round fin tubes). Check the joint for leaks by means of a dye penetrant test.

If leakage still exists: Cut a fin tube that cannot be repaired off at both tubesheets. Close the tube openings in both tubesheets by welding or use tapered plugs to close off the holes. Mount the plug again. Mount the components as described in Chapter Bolt Tightening Sequence for Flanged Connections starting on page 28 Prior to being taken into service the tube bundle must be approved by an official inspector to meet the pressure vessel code/standards requirements.

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Fan Drive Maintenance 6.2 Fan Drives


The operating instructions furnished by the manufacturers of these items shall take priority, in this context refer to Annex to the Fan Drive Chapter starting on page 43 and the drawing of the fan drives.

Attention!
Even if the motor is stopped a dangerously high voltage may exist at the motor terminals. - Danger to life is imminent due to electric shock.

Attention!
Keep a safe distance from all rotating elements. - Contusion and other bodily injuries may be caused.

Attention!
All work on the fan drive unit shall be carried out with a safe foothold gained and otherwise secured, e.g. by means of safety belts/straps. - Falling risks are imminent.

Note:
Guard grills for fan diameters below 2,770 mm (9 ft) must not be stepped on. Guard grills for fan diameters above/equal to 2,770 (9 ft) may be entered after a sufficiently large scaffolding plank has been laid on.

Note:
We recommend that holdbacks be installed to render the fan immovable. Due to free convection and/or wind the fan rotor may also turn when the motor has been switched off.

Note:
The fan-locking must only be done after the motor has been switched off and the fan needs a maximum of 10 seconds for one revolution. It is mandatory to release the fan-lock prior to starting the fan.

Note:
We recommend that vibration switches be installed to prevent damage that may be caused by imbalances, if any.

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Fan Drive Maintenance

Note:
Only use original spares or spares recommended by GEA Luftkhler; otherwise, warranty claims may become forfeited.

Maintenance Intervals of Fan Drives


Fan
1) 1)

as prescribed by manufacturer as prescribed by manufacturer semi-annual

Motor

Belts and pulleys


1)

Maintenance must be performed at regular intervals to be determined by the Owner taking manufacturers instructions, operating conditions and environmental aspects into account.

Fan Bearing System Replace antifriction bearings after 50,000 operating hours The built-in antifriction bearings are filled with grease sufficient for 32,000 hours of continuous operation. During this period a relubrication is not required under normal operating conditions. When this period has elapsed, the fan bearing system must be disassembled by trained personnel in a clean and dry environment, the antifriction bearings cleaned and lubricated with new grease. Regreasing must be done with a lubricant similar to that used for first greasing (for details see Chapter Fan Bearing System). At the same time the antifriction bearings must be inspected and, if necessary, replaced. When regreasing the components the grease usability time can be increased to 50,000 hours of continuous operation. For further information see Chapter Regreasing of Fan Bearing Systems. Under intermittent service the grease has to be replaced after 24,000 operating hours or 4 years whichever comes first. In case there are downtimes exceeding one month the fan drive must be operated for at least 2 hours to make sure moisture that may have ingressed can evaporate and the bearings are adequately lubricated.

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Fan Drive Maintenance

Regreasing of fan bearing systems For regreasing 2 tapped holes M10 each with plug screws are arranged in the antifriction bearing area. To the respective upper tapped holes regreasing nipples can be connected (optional accessory) which may either be threaded directly into the bearing housing or connected below the guard via a lube line (optional accessory). Attention: If the regreasing nipples are directly threaded into the bearing housing the fan must in any case be switched off and locked while regreasing takes place. During regreasing take care to ensure lubricant, lube nipples or lube line are kept clean as foreign matter impairs the smooth running and operational life of the bearings. Relubrication must be done with a lubricant similar to that used for first lubrication (for details see Chapter Fan Bearing System). When relubricating antifriction bearings make sure the below specified intervals and grease quantities are not exceeded. For this purpose the prescribed grease quantity is forced into the heated-up and rotating bearings for abt. 1 minute. Type of bearing Lube points Grease quantity (grams) for relubrication every 12 months appr. 25 appr. 15 appr. 30 appr. 20 appr. 40 appr. 20 appr. 55 appr. 30

75/495 + 155

Inclined radial ball bearings, item 9 Cylindrical roller bearings, item 10 Inclined radial ball bearings, item 9 Cylindrical roller bearings, item 10 Inclined radial ball bearings, item 9 Cylindrical roller bearings, item 10 Inclined radial ball bearings, item 9 Cylindrical roller bearings, item 10

90/XXX + XXX

100/XXX + XXX

115/XXX + XXX

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Fan Drive Maintenance

Cleaning the Fan Drive


Cleaning action taken during maintenance routines helps avoiding imbalances and soiling. If performed, it will usually be sufficient to blow the drive out with water- and oilfree compressed air or to clean by means of a brush. Do not use a high-pressure cleaner or steam-jet cleaner.

Attention!
Wet cleaning may cause damage to the bearings and electrical connections and give rise to short circuiting. - Danger to life is imminent due to electric shock. Dirty belts may also be cleaned by means of a 1:10 glycerine-spirit mixture. Do not use gasoline, benzene, turpentine or similar fluids for this purpose. The use of belt cleaning waxes and sprays is to be avoided. Moreover, sharp-edged objects, wire brushes, emery paper etc. must never be used. All these substances or objects will cause belt damage. Contrary to the belts the pulleys may be cleaned with gasoline or benzene.

Checking the Fan Drives


When performing work on fan drives observe the following: 1. Watch the fan drive to detect imbalances, vibration or unusual noise that may arise. 2. 3. 4. 5. 6. Keep a safe distance from all moving items. Check the belts for true running. Prior to start of maintenance work switch off the power supply. Provide warning signs to alert personnel to the shutdown. Make the fan drive stationary - do not carry out work on rotating drive systems. 7. 8. Inspect all parts to detect signs of wear or corrosion. When work has been completed properly mount all guards again.

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Fan Drive Maintenance

Belt Replacement
1. Slacken existing belts by parallel shifting of the motor using threaded rods - reduce the center distance between large and small pulley. 2. 3. 4. Take off the belt. Clean the pulleys. Check alignment of shafts and pulleys by means of a spirit level or straightedge and adjust alignment as necessary. 5. 6. 7. Renew belts - use complete set furnished by manufacturer. Mount the belts - do not use force. Adjust pretensioning of belts when first mounted by displacing the motor in parallel using threaded rods - increase the distance between large and small pulley. 8. Carefully remove the fan blocking from a safe distance and then leave the fan drive area. 9. Switch on the fan drive and switch it off again after approx. 2 hours of operation. 10. Check belt pretensioning again and adjust if necessary as per instructions shown on the fan drive system drawing.

Fan Bearing System


1. 2. 3. 4. 5. Dismantle the fan bearing system at a clean and dry workplace. Clean the bearing seat and shaft. Check the bearing seat and shaft for abrasion marks. Check the shaft for unbalance. Make measurements to determine whether the bore and outside diameters of the bearings are still within the applicable ISO tolerance zones. 6. If the dimensions are found to be no longer within the tolerance range the bearing seat housings and/or shaft have to be renewed.

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Fan Drive Maintenance

7.

Fill the compartments of the new bearings fully with grease (100 %) and the bearing seats at 50 % - 70 %.

8. 9.

Mount the bearings without using force. Slide the shaft into the housing.

10. Mount new seal rings. 11. Mount the bearing covers on both sides. 12. Slide a parallel key (if any) into the keyway and secure it. 13. Check the fan bearing system for irregularities during operation and unusual noise by making 30 full turns by hand in each direction.

Note:
The amount of force to be exerted varies when turning the shaft manually. 14. Apply a coat of anti-corrosion oil to the shaft ends.

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Fan Drive Maintenance


The following grease volumes are required for the inclined radial ball bearing on the fan and the cylindrical roller bearing on the drive: Type of bearing Lube points Inclined radial ball bearings, item 9 Cylindrical roller bearings, item 10 Inclined radial ball bearings, item 9 Cylindrical roller bearings, item 10 Inclined radial ball bearings, item 9 Cylindrical roller bearings, item 10 Inclined radial ball bearings, item 9 Cylindrical roller bearings, item 10 Grease volume (grams) First filling appr. 210 appr. 150 appr. 500 appr. 300 appr. 600 appr. 400 appr. 800 appr. 600

75/495 + 155

90/XXX + XXX

100/XXX + XXX

115/XXX + XXX

To suit relevant application temperatures we have used for the bearings lithium-base long-term grease having the following properties: Application temperature Type of grease (First filling in Factory) Designation of grease used Consistency (to NLGI-class) Alternative NLGI class Walked penetration Thickener Dropping point -20C to +140C UNIREX N2 K2N-20 2 3 265-295 Lithium complex soap 300 C UNIREX N2

acc. to DIN 51825 acc. to DIN 51818 acc. to DIN ISO 2137

acc. to DIN ISO 2176

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Fan Drive Maintenance


Fan Drive Troubleshooting
FAN Fan does not start Motor defective Motor contactor has tripped Fan blocked

Replace motor Re-close motor contactor; if repeated tripping occurs reduce blade angles Release fan blocking, otherwise check position of the fan blades in the fan ring

Fan runs at reduced speed only Fan bearing defective Frequency converter (if any) or pole changing (if any) defective Poor performance Fan/motor switched off Bad blade angle Motor speed reduced High running noise Fan blades are incorrectly balanced or wrongly mounted Fan bearing defective Motor bearing defective

Replace the fan bearing Replace frequency converter or pole changing device

Switch fan/motor on Set the blade angle to design parameters, or adjust as necessary Increase the motor speed

Check arrangement, mounting and setting angle of the fans Replace the fan bearing Replace motor bearing

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Fan Drive Maintenance

V-BELTS Belt failure after short service time (belt torn apart) Forced mounting causing the pull line to become damaged Drive blocked Effect of foreign objects during operation Drive undersized, number of belts inadequate Extraordinary flank wear Pretension inadequate Startup torque too high Pulley grooves worn out Wrong belt/groove profile Wrong groove angle Pulleys are not flush Recommended minimum pulley diameter fallen below Belt drags or strikes against components

Enable the belt to be mounted without force as prescribed by the mounting instructions Eliminate cause of blockage Mount a protective guard Check the transmission conditions and resize the system

Check pretension and adjust as necessary Check the transmission conditions and resize the system Replace pulleys Take steps to have belt and groove profiles coincide Rework or replace pulleys Align pulleys as necessary Increase the pulley diameter (new drive dimensioning); use special design variant Remove interfering components; newly align the drive sysem

Breakage and cracks in belt body ply (embrittlement) Influence of an outer pulley not in line with the manufacturer recommendations as regards arrangement and diameter High belt slippage

Follow manufacturers recommendations, e.g. increase the diameter; arrange a pulley on belt slack side acting from inside to outside; use special design type Retighten drive system as per mounting instructions, check drive configuration and resize, if necessary Make sure minimum pulley diameter is provided; use special design type

Minimum pulley diameter fallen below

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Fan Drive Maintenance

Excessive influence of heat Excessive influence of cold Chemical influence Belts spongy and sticky Influence of oil, grease, chemicals

Eliminate the heat source, shield; improve the circulation of air; use special design types Heat belts prior to startup; use special design types Shield the drive system; use special design types

Make sure transmission is protected against external influences; use special design types; clean pulleys with gasoline or benzene before mounting new belts

Belts are twisting Wrong belt/groove profile Pulleys are not flush Pulley grooves are severely worn out Pretension inadequate Excessive vibration Foreign objects in pulley grooves

Take steps to have belt and groove profiles coincide Align pulleys as necessary Replace pulleys Retension the transmission system Mount a damping pulley/roll on the belt slack side acting from inside to outside; use joined V-belts Remove foreign objects and shield transmission system

Strong vibrations Undersized transmission system Center-to-center distance significantly greater than recommended by manufacturer High shock loads Pretension inadequate Grooved pulleys not balanced

Check the transmission conditions and resize the system Reduce center distance; mount damping pulley/roll on the belt slack side acting from inside to outside; use joined V-belts Use joined V-belts; mount damping pulley/roll; use special design type Adjust the pretension Balance pulleys

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Fan Drive Maintenance

Belts can no longer be retensioned Center distance adjustment capability insufficient Excessive belt expansion due to undersizing Wrong belt length High running noise Pulleys are not flush Pretension inadequate Transmission system overloaded

Change the adjustment capability as recommended by the manufacturer Recalculate and resize the transmission system Use shorter belt length

Align pulleys as necessary Check pretension and adjust as necessary Check the transmission conditions and resize the system

Non-uniform belt expansion Pulley grooves defective Used belts combined with new belts to form a set Different belt makes have been used in a set

Replace pulleys Replace the entire belt set Only use belts of a single manufacturer to form a set

Annex to the Fan Drive Chapter


Drawing fan bearing Operating instructions of the fan manufacturer Operating instructions of the motor manufacturer Operating instructions of the vibration switch Operating instruction fan bearing Operating instructions of the V-belt manufacturer

Sub-supplier documentation follows withe the final air cooler documentation

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Maintenance of Louvers

6.3

Louvers
Louvers Maintenance Intervals
(Depends on location: snow, dirt, birds, leaves etc.) Cleaning of louvers...................................................to be determined by Owner Inspection of louvers ................................................to be determined by Owner Drives/actuating equipment ......................................to be determined by Owner Crank drive ................................................................ to be greased once a year

Cleaning
Carefully clean the louvers, for example using a steam-jet cleaner or rag, hot water and domestic cleaning agents. Dry dust may usually be blown away by applying compressed air.

Checks
Check the louver blades and louver drives for correct functioning and tight sealing. Check the drive linkage and blade supporting elements. If the drive linkage is found to be bent or bushes of the blade supports damaged these components must be replaced. Check the louver blades and louver drives for correct functioning and tight sealing.

Note:
No objects must be placed on the louvers. The louvers must not be entered or stepped on.

Attention!
Never reach into our touch moving parts. - Contusion and other bodily injuries may otherwise be caused.

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Maintenance of Louvers
Louvers Troubleshooting
The louvers cannot be opened Snow, ice or other deposits are found on the louver blades The drive mechanism jams or is heavily soiled Power supply to the drive is interrupted Louver blades cannot be closed The drive mechanism jams or is heavily soiled

Clean louvers Make drive mechanism and blade bearing system workable, clean if necessary Repair the power supply system

Make drive mechanism and blade bearing system workable, clean if necessary

Louver blades cannot be closed entirely Power supply to the drive is interrupted Deposits are found on the blades of the louvers Pushrod of the drive mechanism is incorrectly adjusted

Repair the power supply system Clean louvers Adjust the length of the pushrod as necessary, fix adjusted system

Louver blades cannot be opened entirely Pushrod of the drive mechanism is incorrectly adjusted

Adjust the length of the pushrod as necessary, fix adjusted system

Annex pertinent to the louvers

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Transportation and Storage

7 Transportation and Storage


7.1 Transportation
Attention!
During transportation via truck, rail, ship or similar transporting means all the equipment and components must be safely shimmed, adequately secured and properly lashed.

Attention!
Regarding parts packed in boxes a marking is to be affixed indicating the handling method to be employed. Handling by means of forklift truck is only permitted if this is clearly marked on the box. Parts in bundles must not be lifted by forklift truck. Otherwise, handling damage and safety hazards are likely to occur.

Packing and Marking


Structural steel components are delivered unpacked. Items that belong together are bundled and secured using steel straps. Metal tags are used for identification purposes. The tube bundles are delivered unpacked. The pipe connections on the tube bundles are closed off by plastic covers. In the event of black material the flange sealing faces are coated with an easily removable metal protective agent. The identification of the tube bundles can be seen on the rating plate located at the inlet header. Parts of the fan drive (fan blades, bearings and motors etc.): The location and type of marking can be taken from the operating instructions issued by the individual manufacturers. Minor items and connecting materials are identified by stickers and lettering on the packages.

Note:
Identical, compatible items have the same identification. Upon delivery of the air cooler proceed as follows: Check the condition and completeness of each partial consignment based on the respective shipping note.

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Transportation and Storage

Check the completeness of the entire shipment by comparing all shipping notes with the bill of material of the consignment.

In the event of damage or missing items: Document this and inform GEA Luftkhler GmbH accordingly without delay.

For tube bundle lifting proceed as follows: Carefully attach via shackles four ropes or straps of equal length at the bores provided for this purpose. The spreading angle of the ropes must exceed 60.

Bore for attaching lifting tackles (tube support) Bore to attach lifting tackles (side wall)

Note:
Whether your equipment is hoisted via the tube supporting location or side wall can be seen from the enclosed drawing.

Note:
Do not place shackles and tools on the fin pack!

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Transportation and Storage 7.2 Storage


Store all components of the air cooler on clean and level ground of adequate load carrying capacity sorted according to construction groups. Steel structure components must only be stored in horizontal position. Support all components by means of sufficiently sized square timber (for steel structure parts use at least size 14 x 14 cm, use pallets to support compact components) to prevent sagging, distortion, slippage or turnover. Make sure the storage location is properly ventilated. Store all items such that they cannot be damaged by their own weight or the weight of other components. Flange connections permitting a maximum of two tube bundles may be stacked on each other. Do not place any items on the fin tubes. In case of items used for steel structures verify that the identification tags are undamaged and in place. Check on a monthly basis the corrosion protective coat we applied to headers and flange sealing faces.

Note:
If the corrosion protective coating on the flange sealing faces has suffered damage or only slight damage it is to be renewed altogether immediately.

Note:
Unless otherwise specified in the order, steel headers have been provided with a two-layer priming coat (film thickness approx. 60 m). The final corrosion protective coat will usually be applied when the piping has been connected and depends on local environmental conditions and customers wishes regarding durability and color shades desired for the installation. Remedial action can thus be taken if damage to headers and pipework occurs during erection.

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Transportation and Storage

Store all parts of the fan drive in dry, ventilated and dustfree surroundings. Machined parts that have not been preserved must be coated with a corrosion protective agent, ESSO Rustban 397 or an equivalent product. When the fan bearing system has been stored for more than 12 months the condition of the grease must be checked. If it is found that the grease contains impurities (ingressing condensate causes the grease consistency to change) it has to be replaced. If no regreasing is carried out the grease service life is limited to 24,000 operating hours.

After the fan bearing system has been stored for more than 3 years the grease must always be replaced. Store motors in a dry, dustfree and moderately heated room. Louver blades and louver actuating components must be stored on level ground in a dustfree and dry environment.

Hoist louvers only via the lifting lugs provided for this purpose. A maximum of 8 louver elements may be stacked on each other. Store V-belt pulleys (their manganese phosphate coating has to be checked monthly and must be renewed as necessary) in a dustfree and dry environment.

Store V-belts at a temperature ranging between +15 C and +25 C and make sure they are not in contact with fumes of chemicals, solvents, fuels and lubricants or acids or exposed to sunlight or artificial light emitted by fluorescent lamps. If V-belts are suspended for storage the diameter of the mandrel/pin from which they are suspended must at least be 10-times the height (thickness) of the V-belt.

All minor parts of the air cooler and connecting materials shall be stored in a dustfree and dry environment.

After the components have been stored in place check whether they have suffered damage.

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Transportation and Storage


Storage Exceeding Three Months
The flange connections on the tube bundle must be positively closed off by covers and the tube bundle is to be filled with nitrogen. A slight gage pressure (0.5 bar) is to be maintained within the tube bundle and indicated by an attached pressure gage.

Note:
Check the pressure gage monthly to verify that a slight overpressure exists in all tube bundles. Bear in mind that sun radiation and changing ambient air temperatures may cause the nitrogen pressure within the tube bundle to vary. In the event of doubt, get in touch with GEA Luftkhler GmbH. If necessary, carefully replenish the nitrogen filling via the existing connecting plug valve.

Note:
Bear in mind that fin tubes, especially those provided with groovemounted (G-Fin) and wound-on aluminum fins (L-Fin), are unprotected and thus prone to suffer damage due to environmental influences.

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Erection Prerequisites

8 Erection
Attention!
Before performing work within the context of this chapter refer to the pertinent design drawings. If disregarded, erection mistakes, future malfunction and safety hazards may be encountered.

8.1

Verifying Prerequisites
Note:
Depending on the supply scope and design version of the air cooler the erection/assembly of individual construction groups as described in the following chapters may be dispensed with in part or even entirely. In the event of deviations the work steps outlined shall be performed analogously. If so desired GEA Luftkhler GmbH can be commissioned to perform the erection. Make sure the mounting location is suitable for the cooler. As a rule, a structural engineer and, if necessary, other technical experts such as environmental and fire prevention professionals must be consulted to assess the situation. Permits issued by the authorities have to be obtained. Make sure the air cooler is erected as prescribed on the layout drawing. Foundations shall be made as per the load diagram; boreholes, drilling pattern and loads shall be taken into account. By way of the shipping bill of material and design drawings check whether all components required are available.

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Erection of the Steel Structure 8.2 Mounting the Steel Structure


Note:
The fin tubes extend in longitudinal direction as indicated below. The headers extend in transverse direction as indicated below. Illustration of directions: fin tubes side wall header longitudinal direction transverse direction
Page 52 of 63

Note:
To enable the components to be properly arranged, major items have been identified, see Chapter Packing and Marking starting on page 46. Identical, compatible items have the same identification. The correct position of the marked items is to be taken from the design drawings.

Note:
Depending on the supply scope and design of the air cooler some of the following work steps can be dispensed with if a more simple design variant is provided.

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Erection of the Steel Structure


Preassembly of Steel Structure Elements
1. If no longitudinal and cross girders are provided so that steel structure elements need not be preassembled: Lift the plenum chambers one after the other. Place the relevant columns below the plenum chamber corners and connect them with each other. Mount the required diagonal bracings. Perform the work outlined in the chapter Aligning the Steel Structure Elements starting on page 56. plenum chamber

bracing

columns

If columns must be connected by longitudinal and cross girders it is expedient in the interest of a smooth air cooler mounting and if enough space is available to preassemble individual items thus forming them into groups.

columns

cross girders

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Erection of the Steel Structure


2. Put the columns on a flat surface on the ground and bolt them to the longitudinal girders and pertinent bracings thus forming individual groups or elements. Also assemble all platform brackets, pipework supports and other parts unless these can only be mounted when the structure is in upright position. Take care to tighten all bolts firmly. 3. If desired, stack the elements preassembled in this manner. A maximum of 5 elements may be stacked on each other. Expediently, stack these elements in the order they are needed for future erection activities. 4. If expedient, bolt the walkways to the pertinent coverings and handrails the stairs sections to the pertinent handrails the access ladders to the respective cages. Take care to tighten all bolts firmly. These elements must not be stacked. 5. 6. Assemble the fan rings on a flat and level base/ground. Fan rings may be stacked, if necessary. A maximum of 3 fan rings may be stacked on each other.

Note:
Make sure to use four ropes of equal length when lifting the fan rings and plenum chambers. For lifting of the plenum chambers attach the ropes at the four holes in the ribs in the bottom sections. 7. Assemble the plenum chambers.

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Erection of the Steel Structure


Erecting the Steel Structure
In the mounting work steps described below those steel structure elements have to be erected first that are connected by means of diagonal bracings.

diagonal bracings

Note:
In the work steps described hereunder all elements and parts must be connected by the respective bolts. The bolts must not yet be ultimately tightened because the steel structure has to be aligned before. 8. Erect the first element consisting of columns, longitudinal girders and bracings and place the element on the respective foundation. Hold the element securely, for example using cable winches. 9. Set up the second adjacent element and place it on the respective foundation. Connect both elements at the transverse sides via the respective cross girders and other bracings to form a complete unit. 10. Put the plenum chamber on the unit and connect both items. 11. Mount the required walkways, stairs sections and access ladders to the transverse sides of the erected structure. 12. Proceed by setting up further elements and place them on the respective foundations. Connect the newly set up element with the already mounted unit using cross girders and further bracings and struts as necessary. In case of air cooler design types providing for the fan drives to be arranged below the tube bundles: Put the plenum chamber on the columns and connect the elements. Another element must only be erected and placed on the respective foundation when this has been done.

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Erection of the Steel Structure


Aligning the Steel Structure Elements
When all elements have been erected and connected with each other (in the case of longer steel structures also when half of the elements have been set up) do the following: 13. Adjust/offset differences in elevation between the columns (maximum deviation between columns in every direction: +/- 5 mm). For this purpose, use plates as shims underneath the columns. 14. Align the steel structure. Now tighten all bolted connections firmly. 15. Attach the fan rings to the plenum chambers.

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Mounting the Fan Drive 8.3 Mounting of Fan Drives


Note:
Before carrying out the following work steps the complete documentation furnished by the manufacturers of the fan drive system components (fan blades, motors, V-belts, gearbox etc.) shall be thoroughly read. Refer to the chapter Annex to the Fan Drive Chapter starting on page 43.

Note:
In case of an air cooler where the fan drive system is arranged above the tube bundles (induced-draft type fan) proceed as follows: First perform the work steps listed in Chapter Mounting the Tube Bundles starting on page 59. Following this, mount the plenum chamber. When this has been done carry out the work steps described in this chapter.

Preassemble the Fan Drive System


1. 2. Jack up the fan support bridge. Mount the fan bearing in the fan support bridge.

Note:
The following work must only be carried out by staff members familiar with the Taper-Lock system. 3. 4. Mount the motor onto the fan support bridge. Mount the small V-belt pulley on the motor shaft and the large pulley on the fans bearing system. 5. 6. 7. Mount the V-belts. Mount the fan hub on the fan bearing unit. Mount the fan blades. In this context refer to the operating instructions of the fan starting on page 43. 8. Protect the shaft journals on the motor and the fan bearing by applying a coat of anti-corrosion oil. 9. Tension the belts.

10. If provided, mount the sound-proofing enclosures on the motors.

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Mounting the Fan Drive


Installing the Fan Drives
11. Lift the fan drives into the fan rings. 12. Align the fan drives in the fan rings such that a uniform circumferential gap is achieved between fan blades and fan rings. 13. Adjust on one fan blade the angle prescribed on the respective design drawing. Mark the position of the fan blade on the inside of the fan ring and adjust all other fan blades so as to coincide with this position. In this context observe the instructions given by GEA Luftkhler GmbH in chapter Annex to the Fan Drive Chapter starting on page 43. 14. Mount the guard grills. The guard grills may only be walked or stepped on if the air cooler fan diameter is 2770 mm or larger and a scaffolding plank or board has first been laid on the guard grill. 15. Make sure the fan drive units can freely rotate and no objects project into the fan rings. After all fan drives of the item number have been installed the drives can be electrically connected. 16. This is to be noted down in the air cooler inspection report.

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Installing the Tube Bundles 8.4 Installing the Tube Bundles


Note:
The covers mounted on the flanges of the tube bundles to protect the sealing faces and prevent the ingress of foreign matter must only be removed when the flanges are connected to the piping system.

Note:
The tube bundles of a given item number are interchangeable. 1. If necessary, mark the position of the tube bundles on the plenum chamber to facilitate the alignment later on.

Note:
When mounting the tube bundles pay attention to the correct position of the fixed and floating side (with expansion studs). 2. Place the tube bundles on the plenum chambers. Connect both without tightening the bolted connections firmly. 3. Align all tube bundles of the given item number. Now tighten all bolted connections firmly. 4. Tighten the header bolts/plugs at the prescribed final torque rates (see tube bundle drawing) to check the compression behavior of the seals/gaskets. 5. Close off the gaps between plenum chamber and tube bundle. For this purpose mount the respective sheeting using the fastening materials (clamps, clips, clip bolts etc.). The open boreholes in the side walls must not be closed off (rainwater drains). 6. Note down the end of the tube bundle mounting work and include release note for connection of the piping systems in the air cooler inspection report. 7. 8. 9. Remove the transport locks on the louver blades prior to mounting. Hoist the louvers only via the lifting lugs provided. Do not lift a louver system consisting of several elements or neither louvers attached or connected to a tube bundle. 10. Connect the louver elements with each other; attach the drive linkage to the driver; mount the resetting spring and secure it.

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Installing the Tube Bundles

11. Connect the electrical and/or pneumatic actuators and positioning elements as per the manufacturers operating instructions. 12. Operate the positioning cylinder once in disconnected condition to avoid damage. 13. Note down the approval for connection in the air cooler inspection report. 14. Fill in the air cooler inspection report with respect to the entire mounting/erection work. Note down any rework that may still have to be performed.

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Installation Instructions 8.5 Installation Instructions


Note:
The connection of pipework is within the Owners scope of responsibility and must exclusively be carried out be trained staff.

Note:
The pipes to be connected including shut-off valving etc. as well as utilities (electrical power, air etc.) do not form part of the supply scope.

Note:
We advise against prefabricating the distribution main because of manufacturing tolerances to be observed with respect to the tube bundles.

Notes on the Installation of the Pipework


Attention!
When connecting the nozzles to the piping system: The nozzles of the headers must not be subjected to pressure, tension or torsional forces exceeding the design limits. Forces resulting from thermal influences must also be duly taken into account. Otherwise, leakages or even breakage of nozzles might occur. After the tube bundles have been mounted and tube bundles released for pipework connection proceed as follows: Determine by measurement the nozzle orientation for fabrication of distribution and collecting piping. Duly observe fabrication and installation tolerances. Make the necessary adjustments on site. Remove the covers from flange sealing faces and mount the distribution pipe and manifolds.

Notes on Electrical Equipment Installation


This work should only be performed by specially trained personnel. Cable ducts must not be attached to the tube bundles.

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Installation Instructions

When motors have been installed and fans put into operation check the fans for correct sense of rotation. The correct rotational direction can be seen from the pertinent design drawing. In the event of a wrong sense of rotation the polarity of the motor has to reversed.

Attention!
When holdbacks have been installed a wrong sense of rotation may result in the holdback being destroyed. Information whether and how the blade angels can be adjusted are given in the fan manufacturers operating instructions in the Annex to the Fan Drive Chapter starting on page 43. The use of frequency converters is only permissible when compatible motors are employed. Machines driven via frequency converters require additional protective and monitoring systems. These systems are not included in GEAs scope of supplies unless expressly agreed otherwise in writing. To perform a function text of the positioning cylinders disconnect the linkage. You may now check the cylinder stroke following which the linkage/rods have to be re-connected.

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Fan Trial Run 8.6 Fan Trial Run


A fan trial run is to be carried out when 1. Mounting has been completed Drive system parts have been replaced Convince yourself that no objects project into the fan ring that may cause fan or drive to be damaged. 2. Check with the fan being stationary whether the gap between fan blade tips and fan ring is of approximately equal size. 3. 4. Check whether all protective guards have been properly mounted. Have the motor connected to check whether the fan rotational direction is correct. 5. Briefly switch the motor on and then off again. The correct sense of rotation is counter-clockwise when viewed from below, refer to information on the fan drive drawing. 6. When the motor is running check for unusual noise and sensible vibration; in this context refer to the chapter Fan Drive Troubleshooting starting on page 39. 7. Check the absorbed fan power on the motor; refer to the fan drive drawing. With the blade angles remaining the same the absorbed power rises as the air temperature goes down and vice versa. In case of several fans of equal size, blade profile, for identical tube bundles and the same operating conditions the absorbed power is almost identical. 8. After a trial run of approx. 2 hours switch the motor off and check with the fan being stationary the fan fastening bolts for tightness, see operating instructions issued by fan manufacturer. 9. With the fan being stationary check the belt tension and adjust it if necessary and when deviating from what has been prescribed on the fan drive drawing. 10. Again make sure that no items project into the fan ring and all protective guards have been properly mounted.

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Disposal

9 Disposal
Prior to disposal all materials contained in the equipment have to be carefully separated/segregated.

Take the individual construction groups out of operation. Observe instructions given in chapter Taking the Plant out of Service starting on page 23. Safely disconnect the power supply to the motors.

Depressurize the tube bundle and empty it. Certify that there are no objections to the further utilization/disposal of the items.

Recycle scrap metal via systems provided for this purpose. Recycle the plastic and rubber parts. Recycle electrical/electronic scrap.

Note:
Recycle the entire packing material left on the site.

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Overview of Maintenance Intervals

10 Annex
10.1 Overview - Maintenance Intervals
Recommended Tube Bundle Maintenance Intervals Check tube bundles for leaks .............................................................. monthly Check outside of tubes for dirt/contamination/soiling ..................... monthly Check whether tube connections and fasteners are firm or tightly seatedmonthly Check for corrosion .............................................................................. monthly Cleaning of inner surfaces of tubes ................... to be determined by Owner Recurring inspections as per Operational Safety Ordinance External inspection .......................................................................every 2 years Internal inspection ........................................................................every 5 years Strength inspection.....................................................................every 10 years Fan Drives Cleaning ................................................................... to be determined by Owner Checking the shaft end corrosion protection .......................depends on relevant ................................................................. storage and operating conditions Checking the V-belts ............................................................................... monthly F a n B e ar in g S y s t em Grease service life (continuous operation).................................. 32,000 hours when relubrication occurs ................................. max. 50,000 operating hours Grease service life (intermittent operation) ........................ 24,000 op. hours ............................................................................................ or max. 4 years Replace antifriction bearings ............................ after 50,000 operating hours Louvers Cleaning of louvers...................................................to be determined by Owner Inspection of louvers ................................................to be determined by Owner

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Data Sheets and Design Drawings

10.2 10.3 10.4

Air Cooler Data Sheet


follows withe the final documentation

Design Drawings
follows withe the final documentation

List of Spares
follows withe the final documentation

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