Gas Cooler

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Cover Sheet

Dez 2011 Rev. 0 GEA Luftkhler Chapter 1 Service and Support Page 1 of 63

Operating Manual

Air Cooler

Customer Armax Gaz S.A.

Strada Aurel Vlaicu, Nr. 35A

551014 Sibiu

Romania

Customers order No. 3395/29.06.2011

Codeword GDU

Item No. 01-EA-100 / 02-EA-100

Engineering 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 betweencustomer and manufacturer. Any use other than intended which includes reproduction of the entire or partialdocument in whatever form as well as utilization of its contents or parts thereof is prohibited unless the expresswritten approval of the manufacturer has been obtained. In the event of contraventions compensation for damageswill be claimed. Moreover, further claims will be raised as deemed necessary.

PRELIMINARY

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Overview


Table of Contents

1 Service and Support ........................................................................................................... 42 Introduction ....................................................................................................................... 5

2.1 Preface...................................................................................................................... 52.2 Owners Responsibility ............................................................................................ 62.3 Application Purpose ................................................................................................ 82.4 Operating Principle ................................................................................................. 92.5 Overview of Air Cooler Components ................................................................... 102.6 Safety Instructions ................................................................................................. 11

3 Commissioning................................................................................................................. 163.1 Gas Coolers ............................................................................................................. 16

4 Operation ......................................................................................................................... 184.1 Air Cooler Control.................................................................................................. 18

Switching Off Fans................................................................................................. 19Control via Frequency Converter .......................................................................... 19Blade Adjustment .................................................................................................. 20

4.2 Measures during Cold Periods .............................................................................. 215 Taking the Plant out of Service....................................................................................... 23

5.1 Gas Coolers ............................................................................................................. 23Empty the Tube Bundle......................................................................................... 23Drying ..................................................................................................................... 24Nitrogen Filling ...................................................................................................... 24

6 Maintenance .................................................................................................................... 256.1 Tube Bundle ........................................................................................................... 25

Cleaning of Tube Bundles ..................................................................................... 26Cleaning the Tubes Inside ..................................................................................... 26Bolt Tightening Sequence for Flanged Connections........................................... 28Cleaning the Tubes Outside .................................................................................. 29Checks for Corrosion ............................................................................................. 30Tube Bundle Troubleshooting .............................................................................. 31Repairs .................................................................................................................... 32

6.2 Fan Drives ............................................................................................................... 33Maintenance Intervals of Fan Drives .................................................................... 34Cleaning the Fan Drive .......................................................................................... 36Checking the Fan Drives ........................................................................................ 36

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Overview


Belt Replacement................................................................................................... 37Fan Bearing System ............................................................................................... 37Fan Drive Troubleshooting ................................................................................... 40Annex to the Fan Drive Chapter ........................................................................... 43

6.3 Louvers ................................................................................................................... 44Louvers Maintenance Intervals ............................................................................. 44Cleaning ................................................................................................................. 44Checks..................................................................................................................... 44Louvers Troubleshooting ...................................................................................... 45Annex pertinent to the louvers ............................................................................ 45

7 Transportation and Storage............................................................................................ 467.1 Transportation ....................................................................................................... 46

Packing and Marking ............................................................................................ 467.2 Storage ................................................................................................................... 48

Storage Exceeding Three Months......................................................................... 508 Erection............................................................................................................................. 51

8.1 Verifying Prerequisites .......................................................................................... 518.2 Mounting the Steel Structure............................................................................... 52Preassembly of Steel Structure Elements ............................................................. 53

Erecting the Steel Structure .................................................................................. 55Aligning the Steel Structure Elements ................................................................. 56

8.3 Mounting of Fan Drives ........................................................................................ 57Preassemble the Fan Drive System ....................................................................... 57Installing the Fan Drives ........................................................................................ 58

8.4 Installing the Tube Bundles .................................................................................. 598.5 Installation Instructions ......................................................................................... 61

Notes on the Installation of the Pipework .......................................................... 61Notes on Electrical Equipment Installation.......................................................... 61

8.6 Fan Trial Run .......................................................................................................... 639 Disposal............................................................................................................................. 6410 Annex................................................................................................................................ 65

10.1 Overview - Maintenance Intervals........................................................................ 6510.2 Air Cooler Data Sheet............................................................................................ 6610.3 Design Drawings .................................................................................................... 6610.4 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 Phone +49 (0)234/980-1653

Dept. TAAP Fax +49 (0)234/980-1974

E-mail [email protected]

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

Waldemar Nowinski Phone +49 (0)234/980-1744Dept. TAS Fax +49 (0)234/980-2018

(Installation, repairs etc.) E-mail [email protected]

Ms. Birgit Bordiuk Phone +49 (0)234/980-1742

Dept. TASE Fax +49 (0)234/980-2018

(Miscellaneous spares) E-mail [email protected]

Sales

Our project engineers will be glad to help you find solutions tailored to your

application. Please contact our Sales Manager:

Jrg Brggemann Phone +49 (0)234/980-1953

Dept. TAV Fax +49 (0)234/980-2014

E-mail [email protected]

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

Dez 2011 Rev. 0 GEA Luftkhler Chapter 2 Introduction Page 5 of 63

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 safelystored 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 fol-

lowing 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 sev-

eral 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 cool-

er 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 fol-

lowing 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 pre-

pared 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 equip-

ment 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 par-

ticular with

the Chapter Service and Support starting on page 4Service and Sup-

port

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 condi-

tions are laid down in the air cooler data sheet and design drawings (in Chap-

ter Annexstarting on page 65). If it is desired to change the application pur-

pose the Owner must verify whether the air cooler is suitable and can be ap-

proved 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 admis-

sible 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 im-

prove 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 distrib-

ute 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 ple-num chambers via which it is distributed over the tube bundle.

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 heat-

ing 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 con-

vection.

Air discharged (hot air)

Air intake (air at ambient temperature)

Product IN

(hot)

Product OUT

(cold)

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Function and Design


2.5 Overview of Air Cooler Components

Air cooler (all figures to be regarded analogous)

Fan impeller ring

Tube bundleHeating bundle

Plenum chamber

Fan bridge

Protective guard

Access ladder

Motor bracket

Bracing

Support

Fan blade

Tube bundle (entire unit) Venting flangeTubesheet

Draining flange Inlet flange Outlet flangeHeader

Fin tube (entire unit) TubeFin

V-belt pulleys V-belt MotorFan support

Fan hub

HeaderLouver

Handrail

Guard cage

Platform

Header

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Safety


2.6 Safety Instructions

Safety Symbols

Warning against hazards of general nature to persons, the environ-ment 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 depres-

surize, 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 instructionsregarding safety at work.

Take steps to have the cause of the failure remedied by expertpersonnel without delay.

Do not restart the air cooler before remedial work has been com-pleted and approved.

Warning that hand injuries, contusion and other bodily injuries may becaused. 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 youhave convinced yourself that they have positively stopped and beensecured to prevent movement.

Warning of falling risks. Work on the air cooler must only be performedunder safe working condition, having gained firm and secure foothold,when safeguarded and with due attention paid and a precautionaryapproach taken.

Warning that bodily injuries may occur due to suspended loads. Onlyemploy suitable and approved lifting equipment. Secure loads to pre-vent slipping and overturning during lifting.

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Safety


Warning against danger caused by product spillage. Before tube andheader connections are disconnected the tube bundle must have beendepressurized and cooled down. The tube bundle must be empty andfree from harmful or dangerous substances. The product must be col-lected and disposed of, if necessary. Only if all security concerns havebeen eliminated may work be carried out on the tube bundle.

Warning that danger to life is imminent due to electric shock. Prior tostart 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 andpipework connections, fittings, valves etc.

Warning that personal protective workwear must be worn when carry-ing out work on the air cooler, especially snug-fitting clothes, safetygloves, protective footwear and hard hat, otherwise risk of injuries.

Warning that hearing protection must be worn when carrying out worknear 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

Dez 2011 Rev. 0 GEA Luftkhler Chapter 3 Commissioning Page 16 of 63

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 emergen-

cies;

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 allowingall 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 en-

sure 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 commission-

ing the equipment.

After plant commissioning these filters are to be checked for soiling

and cleaned if necessary. These filters can be removed after a con-

tinuous 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 tempera-

ture, 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 distor-

tion may otherwise arise which may lead to inadmissible tempera-

ture differences and, during cold periods, freeze-up hazards.

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Start-up of Air Cooler

Dez 2011 Rev. 0 GEA Luftkhler Chapter 3 Commissioning Page 17 of 63

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 ex-ceed 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 re-

spective 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 unu-

sual 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 icylouvers. 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

Dez 2011 Rev. 0 GEA Luftkhler Chapter 4 Operation Page 18 of 63

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 require-

ments 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: V1/V2=n1/n2

Power requirement changes take place proportionally to the 3rd power of fanspeed changes: P1/P2=(n1/n2)

3

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 be-

low. In the event the product outlet temperature rises the steps shall be im-

plemented analogously in reverse order.

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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).

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, se-

vere 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 beingadjusted accordingly.

Note:

We recommend that vibration switches are installed to detect inad-

missible vibrations.

Note:

When changing the speed of the fans also observe the operating in-

structions issued by the manufacturer of the motor and frequency

converter included in the Annex to the Fan Drive Chapterstarting on

page 43 as well as the pertinent fan drive drawing.

Product IN (inlet flange)

front fan rear fan

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Blade Adjustment

Should the fans not equipped with blades adjustable during operation a man-

ual 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 Drivesstarting 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 instruc-

tions issued by the fan manufacturer and included in Chapter Annex

to the Fan Drive Chapterstarting on page 43 as well as the perti-

nent design drawings. Perform the work steps listed in Chapter Fan

Trial Runstarting 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 beexpected, the design of the plant as well as other circumstances.

The Owner must therefore determine the steps that have to be tak-

en when low temperatures prevail; in this context refer to the operat-

ing 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 prod-

uct 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 with-

out delay; in this context refer to Chapter Taking the Plant out of

Servicestarting 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 suf-

fered due to low temperature exposure.

Attentively observe the ambient temperature during cold weather (espe-

cially when the medium flow has been stopped).

The following measures which may to some extent be combined if expedientcan be taken in an attempt to prevent the product from freezing or solidify-

ing/stagnating. The effectiveness of the measures taken must be constantly

verified through the Owner by appropriate means. However, if freezing or so-

lidification/stagnation hazards still exist despite the precautionary actions im-

plemented 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 ar-

ranged 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 Tak-

ing the Plant out of Servicestarting on page 23.

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Shutting the Air Cooler Down

Dez 2011 Rev. 0 GEA Luftkhler Chapter 5 Taking the Plant out of Service Page 23 of 63

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 docu-

mented. If louvers are mounted they may remain closed duringthis 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

Dez 2011 Rev. 0 GEA Luftkhler Chapter 5 Taking the Plant out of Service Page 24 of 63

Drying

In case of multi-pass tube bundles:

Blow the residual liquid out of the return sections by means of com-

pressed 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

Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 25 of 63

6 Maintenance

Document all maintenance activities performed indicating date, type of work,

name of maintenance person and signature. Attach the document to this op-

erating 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 IntervalsWe 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 tobe 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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Cleaning of Tube Bundles

For an appropriate tube bundle functioning clean exchanging surfaces are in-

dispensable. 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 ulti-

mately performance drawbacks and damage to the tube bundles will be en-

countered.

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 deter-

mined 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 switchoff 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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In the event of deposits:

Clean the inner surfaces of the tubes.

Collect the cleaning remnants and dispose of them as prescribed by stat-

utory 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 instal-

lation.

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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Round flange Square flange

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 Annexstarting on page 65.

2. Tighten the bolts of the round and rectangular flanges as per the number-

ing sequence shown in the following drawing.

3. When the unit is operated in the high-pressure temperature range re-

tighten all bolts/plugs after 24 hours of operation at the prescribed tor-

ques. However, the numbering sequence shown need no longer be ob-

served now.

Adm. tightening

torque

MA < 100 Nm MA > 100 Nm

to < 300 Nm

MA > 300 Nm to

< 800 Nm

MA > 800 Nm

Step 1 MA 1 = 50%

[Nm]

MA 1 = 50 Nm MA 1 = 50 Nm MA 1 = 50 Nm

Step 2 MA 2 = 100%

[Nm]

MA 2 = MA/2 + 20

Nm

MA 2 = 150 Nm MA 2 = 150 Nm

Step 3 MA = 100% [Nm] MA 3 = MA/3 +

100 Nm

MA 3 = MA/4 + 150

Nm

Step 4 MA = 100%

[Nm]

MA 4 = MA/2 +

300 Nm

Step 5 MA = 100% [Nm]

correct wrong wrong

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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 ac-

cumulating on the first fin tube row. Smaller particles may even enter the se-

cond 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, depressur-

ize the tube bundle and empty it. Disconnect the motors from the powerand 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 clean-

ing jet parallelly to the fin faces. In the event first signs of damage

are noticed or if damage is suspected abort the cleaning activitiesimmediately 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 da-

ta sheet, refer to the Chapter Annexstarting on page 65.

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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 tak-

en.

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 Troubleshooting

Poor performance

Gas bubbles due to inadequate vent-ing

Vent the tube bundle properly

Deposits inside of the tubes or tubesclogged

Clean the tube inside

Outer tube surfaces dirty Clean the outer tube surfaces

If the product is water: Reduced heattransfer due to water containing ahigh amount of cooling agent

Increase the water proportion

Motors switched off or speed ratesreduced

Check motors and speed

The fan blade angle is too small Adjust the blade angle

Leakages

Joints in the tube system or in theheaders are leaky

Make sure sealing faces have proper contact; re-tighten connections in pressureless state, other-

wise replace seals/gaskets

Leakage at the fin tube/tubesheetjoints

Reweld or re-expand the connections or both ifnecessary; otherwise cut off tube and close offthe tube holes in the tubesheet

Corrosion Contact GEA Luftkhler GmbH for information onrepairs

Bent fin tubes

Some tubes are clogged, remain coldand act like tie-rods thus affecting theother tubes

Clear clogged tubes, otherwise cut tubes off andclose off tube holes in the tubesheet

Headers are prevented from expand-ing

Take steps to allow expansion, remove any ob-jects that may impede expansion

Bent fins

Stepped-on fins are damaged or finsdamaged due to objects placed onthem

Do not step on fins before having laid a board,plank or similar pressure spreading object on thefins, be careful when entering; straighten dam-aged fins using flat-nose pliers

Damage caused by high-pressurecleaner or similar device

Reduce the cleaning pressure and apply jet at aright angle to the fin tube; straighten damagedfins using flat-nose pliers

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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 connec-tion.

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 pos-

sible 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 toclose off the holes.

Mount the plug again. Mount the components as described in Chapter

Bolt Tightening Sequence for Flanged Connectionsstarting on page 28

Prior to being taken into service the tube bundle must be approved by an offi-

cial 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 Chapterstarting 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 en-

tered after a sufficiently large scaffolding plank has been laid on.

Note:

We recommend that holdbacks be installed to render the fan im-

movable. 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 dam-

age that may be caused by imbalances, if any.

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Note:

Only use original spares or spares recommended by GEA Luftkh-

ler; otherwise, warranty claims may become forfeited.

Maintenance Intervals of Fan Drives

Fan1)

as prescribed by manufacturer

Motor1)

as prescribed by manufacturer

Belts and pulleys semi-annual

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 hoursThe built-in antifriction bearings are filled with grease sufficient for

32,000 hours of continuous operation. During this period a relubrica-

tion is not required under normal operating conditions.

When this period has elapsed, the fan bearing system must be disas-

sembled by trained personnel in a clean and dry environment, the

antifriction bearings cleaned and lubricated with new grease. Re-

greasing 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 in-

creased to 50,000 hours of continuous operation. For further infor-

mation 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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Regreasing of fan bearing systems

For regreasing 2 tapped holes M10 each with plug screws are ar-

ranged in the antifriction bearing area. To the respective upper

tapped holes regreasing nipples can be connected (optional accesso-

ry) 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 lockedwhile 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 speci-

fied intervals and grease quantities are not exceeded. For this pur-

pose 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 every12 months

75/495 + 155Inclined radial ball bearings,

item 9

appr. 25

Cylindrical roller bearings, item

10

appr. 15

90/XXX + XXXInclined radial ball bearings,

item 9

appr. 30


10

appr. 20


item 9

appr. 40


10

appr. 20


item 9

appr. 55

Cylindrical roller bearings, item10

appr. 30

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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 con-

nections 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 mix-

ture. 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 ben-zene.

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. Keep a safe distance from all moving items.

3. Check the belts for true running.

4. Prior to start of maintenance work switch off the power supply.

5. Provide warning signs to alert personnel to the shutdown.

6. Make the fan drive stationary - do not carry out work on rotating drive

systems.

7. Inspect all parts to detect signs of wear or corrosion.

8. When work has been completed properly mount all guards again.

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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. Take off the belt.

3. Clean the pulleys.

4. Check alignment of shafts and pulleys by means of a spirit level or

straightedge and adjust alignment as necessary.

5. Renew belts - use complete set furnished by manufacturer.

6. Mount the belts - do not use force.

7. 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 op-

eration.

10. Check belt pretensioning again and adjust if necessary as per instruc-

tions shown on the fan drive system drawing.

Fan Bearing System

1. Dismantle the fan bearing system at a clean and dry workplace.

2. Clean the bearing seat and shaft.

3. Check the bearing seat and shaft for abrasion marks.

4. Check the shaft for unbalance.

5. Make measurements to determine whether the bore and outside diame-

ters 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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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 Grease volume (grams)First filling

75/495 + 155Inclined radial ball bearings,

item 9

appr. 210


10

appr. 150


item 9

appr. 500


10

appr. 300


item 9

appr. 600


10

appr. 400


item 9

appr. 800


10

appr. 600

To suit relevant application temperatures we have used for the bearings

lithium-base long-term grease having the following properties:

Application temperature -20C to +140C UNIREX N2Type of grease(First filling in Factory)

UNIREX N2

Designation of grease used K2N-20 acc. to DIN 51825Consistency (to NLGI-class)Alternative NLGI class 23 acc. to DIN 51818Walked penetration 265-295 acc. to DIN ISO 2137Thickener Lithium complexsoapDropping point 300 C acc. to DIN ISO 2176

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Fan Drive Troubleshooting

FAN

Fan does not start

Motor defective Replace motor

Motor contactor has tripped Re-close motor contactor; if repeated trippingoccurs reduce blade angles

Fan blocked Release fan blocking, otherwise check position ofthe fan blades in the fan ring

Fan runs at reduced speed only

Fan bearing defective Replace the fan bearing

Frequency converter (if any) or polechanging (if any) defective

Replace frequency converter or pole changingdevice

Poor performance

Fan/motor switched off Switch fan/motor on

Bad blade angle Set the blade angle to design parameters, oradjust as necessary

Motor speed reduced Increase the motor speed

High running noise

Fan blades are incorrectly balanced orwrongly mounted

Check arrangement, mounting and setting angleof the fans

Fan bearing defective Replace the fan bearing

Motor bearing defective Replace motor bearing

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V-BELTS

Belt failure after short service time (belt torn apart)

Forced mounting causing the pull lineto become damaged

Enable the belt to be mounted without force asprescribed by the mounting instructions

Drive blocked Eliminate cause of blockage

Effect of foreign objects during opera-

tion

Mount a protective guard

Drive undersized, number of beltsinadequate

Check the transmission conditions and resize thesystem

Extraordinary flank wear

Pretension inadequate Check pretension and adjust as necessary

Startup torque too high Check the transmission conditions and resize thesystem

Pulley grooves worn out Replace pulleys

Wrong belt/groove profile Take steps to have belt and groove profiles coin-cide

Wrong groove angle Rework or replace pulleys

Pulleys are not flush Align pulleys as necessary

Recommended minimum pulley diam-eter fallen below

Increase the pulley diameter (new drive dimen-sioning); use special design variant

Belt drags or strikes against compo-nents

Remove interfering components; newly align thedrive sysem

Breakage and cracks in belt body ply (embrittlement)

Influence of an outer pulley not in linewith the manufacturer recommenda-tions as regards arrangement anddiameter

Follow manufacturers recommendations, e.g.increase the diameter; arrange a pulley on beltslack side acting from inside to outside; use spe-cial design type

High belt slippage Retighten drive system as per mounting instruc-tions, check drive configuration and resize, ifnecessary

Minimum pulley diameter fallen below Make sure minimum pulley diameter is provided;use special design type

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Excessive influence of heat Eliminate the heat source, shield; improve thecirculation of air; use special design types

Excessive influence of cold Heat belts prior to startup; use special designtypes

Chemical influence Shield the drive system; use special design types

Belts spongy and sticky

Influence of oil, grease, chemicals Make sure transmission is protected against ex-ternal influences; use special design types; cleanpulleys with gasoline or benzene before mountingnew belts

Belts are twisting

Wrong belt/groove profile Take steps to have belt and groove profiles coin-cide


Pulley grooves are severely worn out Replace pulleys

Pretension inadequate Retension the transmission system

Excessive vibration Mount a damping pulley/roll on the belt slack sideacting from inside to outside; use joined V-belts

Foreign objects in pulley grooves Remove foreign objects and shield transmissionsystem

Strong vibrations

Undersized transmission system Check the transmission conditions and resize thesystem

Center-to-center distance significantly

greater than recommended by manu-facturer

Reduce center distance; mount damping pul-

ley/roll on the belt slack side acting from inside tooutside; use joined V-belts

High shock loads Use joined V-belts; mount damping pulley/roll;use special design type

Pretension inadequate Adjust the pretension

Grooved pulleys not balanced Balance pulleys

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Belts can no longer be retensioned

Center distance adjustment capabil-ity insufficient

Change the adjustment capability as recom-mended by the manufacturer

Excessive belt expansion due toundersizing

Recalculate and resize the transmission system

Wrong belt length Use shorter belt length

High running noise


Pretension inadequate Check pretension and adjust as necessary

Transmission system overloaded Check the transmission conditions and resize thesystem

Non-uniform belt expansion

Pulley grooves defective Replace pulleys

Used belts combined with new belts

to form a set

Replace the entire belt set

Different belt makes have been usedin a set

Only use belts of a single manufacturer to form aset

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 finalair 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 OwnerCrank 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 the-

se 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 bod-

ily 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 foundon the louver blades

Clean louvers

The drive mechanism jams or isheavily soiled

Make drive mechanism and blade bearing sys-tem workable, clean if necessary

Power supply to the drive is interrupt-

ed Repair the power supply system

Louver blades cannot be closed

The drive mechanism jams or isheavily soiled

Make drive mechanism and blade bearing sys-tem workable, clean if necessary

Louver blades cannot be closed entirely

Power supply to the drive is interrupt-ed

Repair the power supply system

Deposits are found on the blades of

the louvers Clean louvers

Pushrod of the drive mechanism isincorrectly adjusted

Adjust the length of the pushrod as necessary, fixadjusted system

Louver blades cannot be opened entirely

Pushrod of the drive mechanism isincorrectly adjusted

Adjust the length of the pushrod as necessary, fixadjusted system

Annex pertinent to the louvers

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Transportation and Storage

Dez 2011 Rev. 0 GEA Luftkhler Chapter 7 Transportation and Storage Page 46 of 63

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 indicat-

ing the handling method to be employed. Handling by means of fork-

lift 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 to-

gether 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 letter-

ing 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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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 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!

Bore for attaching lifting tackles

(tube support)

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7.2 Storage

Store all components of the air cooler on clean and level ground of ade-

quate 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 turn-

over. 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 max-

imum 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 altogeth-

er 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 envi-

ronmental 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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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 cor-

rosion 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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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 at-

tached 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 andchanging 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 groove-

mounted (G-Fin) and wound-on aluminum fins (L-Fin), are unpro-

tected and thus prone to suffer damage due to environmental influ-

ences.

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Erection Prerequisites

Dez 2011 Rev. 0 GEA Luftkhler Chapter 8 Erection Page 51 of 63

8 Erection

Attention!

Before performing work within the context of this chapter refer to the

pertinent design drawings. If disregarded, erection mistakes, fu-

ture malfunction and safety hazards may be encountered.

8.1 Verifying PrerequisitesNote:

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 en-

tirely. In the event of deviations the work steps outlined shall be per-

formed 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 en-

vironmental and fire prevention professionals must be consulted to as-

sess 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 wheth-

er 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:

Note:To enable the components to be properly arranged, major items

have been identified, see Chapter Packing andMarking starting on

page 46. Identical, compatible items have the same identification.

The correct position of the marked items is to be taken from the de-

sign 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 de-

sign variant is provided.

transverse direction

fin tubes

side wall

header

longitudinaldirection

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Preassembly of Steel Structure Elements

1. If no longitudinal and cross girders are provided so that steel structure el-

ements need not be preassembled:

Lift the plenum chambers one after the other.

Place the relevant columns below the plenum chamber corners and con-

nect them with each other.

Mount the required diagonal bracings.

Perform the work outlined in the chapter Aligning the Steel Structure El-

ementsstarting on page 56.

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 availa-

ble to preassemble individual items thus forming them into groups.

columnsbracing

plenum chamber

cross girderscolumns

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2. Put the columns on a flat surface on the ground and bolt them to the lon-

gitudinal 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 up-

right position. Take care to tighten all bolts firmly.

3. If desired, stack the elements preassembled in this manner. A maxi-

mum 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. Assemble the fan rings on a flat and level base/ground.

6. Fan rings may be stacked, if necessary. A maximum of 3 fan rings maybe 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 at-

tach the ropes at the four holes in the ribs in the bottom sections.

7. Assemble the plenum chambers.

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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.

Note:

In the work steps described hereunder all elements and parts must

be connected by the respective bolts. The bolts must not yet be ul-

timately tightened because the steel structure has to be aligned be-

fore.

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 foun-

dation. 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.

diagonal bracings

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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 de-

viation 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

Dez 2011 Rev. 0 GEA Luftkhler Chapter 87BErection Page 57 von 63

8.3 Mounting of Fan Drives

Note:

Before carrying out the following work steps the complete documen-

tation furnished by the manufacturers of the fan drive system com-

ponents (fan blades, motors, V-belts, gearbox etc.) shall be thor-

oughly 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

Bundlesstarting 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. Jack up the fan support bridge.

2. Mount the fan bearing in the fan support bridge.

Note:

The following work must only be carried out by staff members famil-

iar with the Taper-Lock system.

3. Mount the motor onto the fan support bridge.

4. Mount the small V-belt pulley on the motor shaft and the large pulley on

the fans bearing system.

5. Mount the V-belts.

6. Mount the fan hub on the fan bearing unit.

7. 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

Dez 2011 Rev. 0 GEA Luftkhler Chapter 87BErection Page 58 von 63

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 Chapterstarting 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 elec-

trically connected.

16. This is to be noted down in the air cooler inspection report.

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Installing the Tube Bundles

Dez 2011 Rev. 0 GEA Luftkhler Chapter 8 7BErection Page 59 of 63

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 on-

ly 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 cham-

ber to facilitate the alignment later on.

Note:

When mounting the tube bundles pay attention to the correct posi-

tion of the fixed and floating side (with expansion studs).