gas cooler
TRANSCRIPT
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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
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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
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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
Dez 2011 Rev. 0 GEA Luftkhler Chapter 1 Service and Support Page 4 of 63
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
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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
Dez 2011 Rev. 0 GEA Luftkhler Chapter 2 Introduction Page 6 of 63
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
Dez 2011 Rev. 0 GEA Luftkhler Chapter 2 Introduction Page 7 of 63
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
Dez 2011 Rev. 0 GEA Luftkhler Chapter 2 Introduction Page 8 of 63
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
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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
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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
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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
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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
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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
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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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Capacity Control during Operation
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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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Capacity Control during Operation
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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
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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
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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
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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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Tube Bundle Maintenance
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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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Tube Bundle Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 27 of 63
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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Tube Bundle Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 28 of 63
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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Tube Bundle Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 29 of 63
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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Tube Bundle Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 30 of 63
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 Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 31 of 63
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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Tube Bundle Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 32 of 63
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
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 33 of 63
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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Fan Drive Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 34 of 63
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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Fan Drive Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 35 of 63
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
Cylindrical roller bearings, item
10
appr. 20
100/XXX + XXXInclined radial ball bearings,
item 9
appr. 40
Cylindrical roller bearings, item
10
appr. 20
115/XXX + XXXInclined radial ball bearings,
item 9
appr. 55
Cylindrical roller bearings, item10
appr. 30
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Fan Drive Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 36 of 63
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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Fan Drive Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 37 of 63
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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Fan Drive Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 39 of 63
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
Cylindrical roller bearings, item
10
appr. 150
90/XXX + XXXInclined radial ball bearings,
item 9
appr. 500
Cylindrical roller bearings, item
10
appr. 300
100/XXX + XXXInclined radial ball bearings,
item 9
appr. 600
Cylindrical roller bearings, item
10
appr. 400
115/XXX + XXXInclined radial ball bearings,
item 9
appr. 800
Cylindrical roller bearings, item
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 Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 40 of 63
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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Fan Drive Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 41 of 63
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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Fan Drive Maintenance
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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
Pulleys are not flush Align pulleys as necessary
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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Fan Drive Maintenance
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 43 of 63
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
Pulleys are not flush Align pulleys as necessary
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
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 44 of 63
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
Dez 2011 Rev. 0 GEA Luftkhler Chapter 6 Maintenance Page 45 of 63
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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Transportation and Storage
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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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Transportation and Storage
Dez 2011 Rev. 0 GEA Luftkhler Chapter 7 Transportation and Storage Page 48 of 63
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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Transportation and Storage
Dez 2011 Rev. 0 GEA Luftkhler Chapter 7 Transportation and Storage Page 49 of 63
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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Transportation and Storage
Dez 2011 Rev. 0 GEA Luftkhler Chapter 7 Transportation and Storage Page 50 of 63
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
Dez 2011 Rev. 0 GEA Luftkhler Chapter 8 Erection Page 52 of 63
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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Erection of the Steel Structure
Dez 2011 Rev. 0 GEA Luftkhler Chapter 8 Erection Page 53 of 63
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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Erection of the Steel Structure
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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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Erection of the Steel Structure
Dez 2011 Rev. 0 GEA Luftkhler Chapter 8 Erection Page 55 of 63
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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Erection of the Steel Structure
Dez 2011 Rev. 0 GEA Luftkhler Chapter 8 Erection Page 56 of 63
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).